Hanbell RC2-100 Installation manual

HANBELL COMPRESSOR
INSTALLATION & START-UPGUIDE
RC2-100 TORC2-930
Rev M.5.2
WARNING!
NO OIL is shipped in compressor.
Compressor must NEVER be run backwards.
These Safeties ARE Required at Startup to Maintain Hanbell Warranty
a) Motor Module Trip (INT69HBY): Open for 1 second
b) Low Oil Level Float Trip: Open for 30-60 seconds
c) Unsafe Suction: Less than 5 psi for 3 seconds
d) Low Differential Pressure: Less than 65 psi for 60 seconds (Oil Psi – SuctionPsi)
e) Unsafe Differential Pressure: Less than 35 psi for 5 seconds (Oil Psi – SuctionPsi)
f) Low Discharge Superheat: Less than 25°F for 300 seconds Revision –10/02/19

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The MCS Commitment: Our commitment is to provide practical solutions for the industry’s needs and to be both a
leader and a partner in the effective use of microprocessor controls.
Micro Control Systems, Inc.
5580 Enterprise Parkway Fort
Myers, Florida 33905 Phone:
[phone]
Fax: [phone]
www.MCScontrols.com
(Website contains product descriptions, manuals, software releases and troubleshooting aids among others)
All information contained within this document is considered to be proprietary information of Micro Control Systems, Inc. No
information or data from this document shall be published, used, reproduced, transmitted, or disclosed to others outside your
organization without the prior expressed written consent of Micro Control Systems, Inc. This document and the information
contained herein shall be treated as proprietary. Reasonable provisions shall be provided to ensure that this information
remains proprietary by your employees, agents and other personnel that may have access to this document.
Revision:
Date
Author
Description of Changes
12/03/12 M. Schreiber / X. Beltran
Update Manual to REV H
Updated Hanbell Liquid Injection Piping
ATTENTION: Step Control Loading Plate Design In RC2Series
Added Revision Chart
Updated / Added Solenoid Installation & AlignmentPictures
12/06/12 M. Schreiber Update Manual to REV I
Added Hanbell Compressor Picture
05/24/13
M. Schreiber
Update Manual to REV J
Updated Hanbell Liquid Injection Piping
Added Hanbell Flooded Type Compressor with Oil Separator
06/13/13 M. Schreiber Update Manual to REV K
Updated Hanbell Liquid Injection Piping
6/18/13 K. Mitchell
Update Manual to Rev L
Updated wiring of electrical power terminals
Added rotation of compressor
Inserted Tableof Contents
11/04/14 X. Beltran
Update Manual to Rev M
Updated Installation Procedures (Liquid InjectionSolenoid)
Updated INT69HBY diagnose wiringdiagram
Updated Hanbell Flooded Typediagrams
Updated images Hanbell VFD &Solenoids
7/30/15 DEW Update Manual to Rev N
Update page 11
8/27/15
DEW
Update section 13
11-16-16
DEW
Replace dwg pg 6, 7,9, 212. 22
04-18-17
DEW
Add Warranty Maintenance Info in back
11-27-17
DEW
Edits to pages 11,12,13 picked up from App097
12-28-17 DEW add POE OIL Warning
09-05-17
DEW Add Note on Economizer, Drawing

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Table of Contents
Compressor Crate Unpacking & Inspection.......................................................................................................4
Compressor Safety Instructions.........................................................................................................................5
Installation Procedures......................................................................................................................................5
Recommended Liquid Injection Piping...............................................................................................................6
Screw Compressor Wiring Procedures..............................................................................................................7
INT69HBY.......................................................................................................................................................12
Maintenance Area Requirement ......................................................................................................................18
Compressor Piping..........................................................................................................................................20
Electrical Wiring...............................................................................................................................................20
Pre-Start-up Procedure....................................................................................................................................21
Start-up Procedure..........................................................................................................................................25
Recommended Safety Settings .......................................................................................................................25
Hanbell with VFD.............................................................................................................................................26
Solenoids ........................................................................................................................................................27
Slide Amp Calculation......................................................................................................................................34
Handling POE Oil Information..........................................................................................................................39
Warranty / Maintenance Information................................................................................................................40

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1. Compressor Crate Unpacking & Inspection
1.1. Inspect crate and compressor for anyshipping
damage.
1.2. The compressor is in an easy open crate, cutstraps
and lift off crate top from base.
1.3. Use either steel cable or safety ropes to lift the
compressor, see Figure 1. The cable shouldbe
capable of holding up to a minimum of 2 tons.
Use caution while lifting the compressor
Figure 1
Lifting Compressor with Steel Cable
⇒Make sure that the steel cable does not touch the Solenoid Valves, Capillary, Oil Heater, Discharge
Temperature Sensor and or Power Terminals, etc. to prevent damage.
⇒Use only steel cable or safety ropes to lift the compressor; make sure that the cable/rope has the
proper strength to lift the compressor.
⇒Keep the compressor horizontal while lifting.
1.4. Check compressor nameplate for correct model and voltage designation.
1.5. To facilitate customer installation requirements, the parts listed in Table 1 are factory supplied in separate boxes
located in the compressor terminal box or packed in the compressor shipping container. Please verify that you
have received all accessory parts.
Table 1: Compressor Accessories & Service Valve Parts
Qty
Description
1
Stop Valve Assembly
1 stop valve, 2 gaskets, 1 charging valve, 4 bolts, 1 half union connector, 1 flare nut, 1 flare seal
bonnet
1
Discharge bushing connector
1
Suction bushing connector
1
Motor Terminal Junction Box Assembly
1 terminal box, 1 motor protection, 2 plastic terminal plugs, 1 reset button, 4 wires
(refer to Figure 4-B)

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2. Compressor Safety Instructions
2.1. Follow recognized safety procedures and practices.
2.2. In order to prevent the penetration of moisture, air or impurities, the compressor has been charged with Nitrogen
gas. Do not remove any compressor bolts or fittings until the factory supplied holding charge has been relieved
2.3. Do not apply any power to the compressor unless all valves are open and solenoids are energized (suction /
discharge, service valves, economizer and oil shut off valves).
2.4. Do not operate or provide any electrical power to the compressor unless the terminal box cover is in place and
secured. Measurements of the current and voltage during running conditions must be taken at other points in the
power supply.
2.5. Do not remove terminal box cover until all electrical sources have been disconnected.
WARNING: Failure to follow these instructions could result in serious personal injury.
3. Installation Procedures
3.1. Holding Charge: The screw compressor is factory supplied with 7 psig (0.5 bar) holding charge of nitrogen gas.
The internal pressure must be relieved before attempting to remove any compressor fittings or parts. Relieve the
holding charge by removing the threaded cap on the low pressure Schrader connection fitting and depressing
the internal Schrader stem.
CAUTION: This compressor may contain trace amounts of oil. Do not relieve the holding
charge or open the compressor pots until it is ready to be connected to a closed dry system.
Excessive moisture may shorten compressor life.
3.2. Installation of the Compressor Electrical Terminal Box: Four bolts located on the top of the electrical terminal
box cover mount the electrical terminal box; it is adjustable to the cable hole direction to meet the power cables’
optional connection direction from the chiller.
3.3. Oils: Adding and removing oil is done through the Drain valve located on the solenoid side of compressor. The
compressor has no oil and is not charged with oil. When adding or doing a complete change, use only the
listed Hanbell approved oils. POE oils readily absorb moisture and cause acid formation in the system.
Keep oil exposure to the atmosphere to a minimum.
3.4. Installation of the Service/Stop Valve: Unpack the service/stop valve’s box then check against the list on the
outside of the box to ensure correct parts. Be sure that all parts inside the carton are clean. Use the four bolts to
secure the service/stop valve. Use PTFE sealer to seal the adapter while tightening it. Please refer to Figure 5-A
for space requirements for future service and maintenanceneeds.
3.5. Service/stop Valve Recommended Connection
Figure 3-A RC2-100, 140& 180 Figure 3-B RC2-170, 200~580 & 620 Figure 3-C RC2-610, 710~930

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3.6. Liquid Injection Solenoid Valve and Expansion Valve (Required, Not included with compressor): The
liquid injection system may be piped, but it is necessary to consider the required space for adjustment of the
expansion valve while testing or running the compressor. Please refer to installation guide in the following
section for connection points.
3.7. PTC Discharge Temperature Protection: Each compressor comes standard with three PTC sensors in the
motor windings and one located at the discharge port. A motor module (INT69HBY) is installed in the electrical
terminal box. Refer to Figure 4-B showing the connection of motor and discharge PTCs in series to the motor
module corresponding terminal blocks.
4. Recommended Liquid Injection Piping
Note A: It is necessary to adjust the Ball Valve to feed small amounts of liquid (drops) to the
compressor motor.

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5. Screw Compressor Wiring Procedures
Following the diagrams below will prevent damage to the electrical terminals and the
possibility of personal injury.

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Terminal
V2
The method to tell the terminals (V-Phase)
1. By alphabet: Refer to the alphabet beside each terminal bolt in a star-delta motor.
2. By numbers: Refer to the number beside each bolt in a PWS motor.

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Figure 5-A Motor Wiring

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5.1. Electrical Power Terminals
The power terminals of Hanbell compressors are made from ceramic materials and well insulated
more than 1000MΩ. Be careful connecting the wiring and follow the list below.
⇒The ceramic part on the power terminal should not be tighten by hitting otherwise the insulation of
the power terminal could be degraded.
⇒Follow the drawing shown below for the wiring to prevent the power terminal from being damaged.
⇒The setting of the torque wrench for tightening the copper nut of the terminal bolts should be set less
than 500 kg-cm (36 pound/inch)
The insulation of the ceramic power terminals are very easily degraded by water, so DO NOT take
the leakage test by immersing the whole compressor in the water. Shut down the chiller first for
service if the insulation valve of the power terminal is lower than 5MΩ.